Method of cyclonic separation of a flow of multi-phase fluid

ABSTRACT

A method of separating a flow of multi-phase fluid includes directing the flow through the inlet opening of an enclosed tubular body comprising a tubular sidewall with opposed end walls, one or more axial outlet apertures formed through the end walls, and one or more radial outlet apertures formed through the tubular sidewall at locations spaced from the inlet opening. The method also includes directing the flow of multi-phase fluid onto one or more swirl plates positioned between the inlet opening and the outlet apertures, with the swirl plates having angled surfaces configured to impart a cyclonic motion to the flow so as to initiate separation of the constituents of the multi-phase. The method further includes directing the gas constituent axially outward through the axial outlet aperture and directing the oil constituent and the water constituent radially outward from the tubular body through the one or more radial outlet apertures.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.17/376,434, filed Jul. 15, 2021, which is a continuation of U.S.application Ser. No. 16/724,023, filed Dec. 20, 2019, now U.S. Pat. No.11,065,559, which claims the benefit of U.S. Provisional Application No.62/784,102, filed Dec. 21, 2018, each of which is incorporated byreference in its entirety herein, and for all purposes.

FIELD OF THE INVENTION

The present invention generally relates to water clarification systems,and more specifically to water clarification systems used in waterprocessing facilities that receive contaminated water fromhydrocarbon-producing wells.

SUMMARY

Briefly described, one embodiment of the present disclosure comprises acyclonic inlet diverter for initiating the separation of a multi-phasefluid received from a fluid source. The cyclonic inlet divertergenerally comprises an enclosed tubular body that is mounted crosswisewithin a larger separator vessel, proximate an inlet end of theseparator vessel. The inlet diverter includes a splitter platepositioned within a center portion of the tubular body and configured tosplit the inlet flow into a first stream and a second stream, as well asone or more swirl plates positioned on each side of the splitter platewith angled surfaces configured to increase the cyclonic motion of thefirst and second streams within the tubular body. The inlet diverterfurther includes an elongate aperture formed through the bottom sidewallportion of the tubular body on each side of the splitter plate, an axialaperture formed through opposing end walls of the tubular body, and oneor more radial apertures formed through lateral sidewall portions of thetubular body proximate each opposing end wall.

The inlet diverter also includes directing the multi-phase fluid fromthe fluid source into the center portion of the tubular body so as tosplit the inlet fluid flow against a leading edge of the splitter plateand induce the cyclonic motion with the swirl plates to initiate theseparation of the multi-phase inlet fluid flow, wherein at least amajority portion of a solids constituent is directed downwardly outwardfrom the inlet diverter through the elongate apertures, at least amajority portion of the gas constituent is directed axially outward fromthe inlet diverter through the axial apertures, and at least a majorityportion of the oil constituent and at least a majority portion of thewater constituent are directed laterally outward from the inlet diverterthrough the one or more radial apertures proximate each opposing end thetubular body.

BRIEF DESCRIPTION OF THE DRAWINGS

The patent application file contains at least one drawing executed incolor. Copies of this patent or patent application publication withcolor drawing(s) will be provided by the Office upon request and paymentof necessary fee.

FIG. 1 is a perspective view of a horizontally-disposed, elongatemulti-phase separator vessel including the cyclonic inlet diverter at aninlet end, in accordance with one representative embodiment of thepresent disclosure.

FIG. 2 is a cross-sectional top view of the separator vessel andcyclonic inlet diverter of FIG. 1 .

FIG. 3 is a cross-sectional side view of the separator vessel andcyclonic inlet diverter of FIG. 1 .

FIG. 4 is a cross-sectional end view of the separator vessel andcyclonic inlet diverter of FIG. 1 .

FIG. 5 is an exterior perspective view of a cyclonic inlet diverter fora multi-phase fluid, in accordance with another representativeembodiment of the present disclosure.

FIG. 6 is a cut-away perspective view of the cyclonic inlet diverter ofFIG. 5 .

FIG. 7 is a top view of the cyclonic inlet diverter of FIG. 5 .

FIG. 8 is an inlet end side view of the cyclonic inlet diverter of FIG.5 .

FIG. 9 is a bottom view of the cyclonic inlet diverter of FIG. 5 .

FIG. 10 is a side view of the cyclonic inlet diverter of FIG. 5 .

FIG. 11 is a lower perspective backside view of the cyclonic inletdiverter of FIG. 5 mounted within a separator vessel, in accordance withyet another embodiment of the present disclosure.

FIG. 12 is a lower perspective side view of the cyclonic inlet diverterof FIG. 11 .

FIG. 13 is a close-up side view of the cyclonic inlet diverter of FIG.11 .

FIG. 14 is a close-up inlet end side view of the cyclonic inlet diverterof FIG. 11 .

FIG. 15 is a close-up underside view of the cyclonic inlet diverter ofFIG. 11 .

FIG. 16 is a schematic diagram of fluid velocities as the inlet flow isreceived into the cyclonic inlet diverter of FIG. 5 through the inletport and encounters the splitter plate.

FIG. 17 is a schematic diagram of fluid velocities within the cyclonicinlet diverter of FIG. 5 as the inlet flow travels from the splitterplate through the swirl plates.

FIG. 18 is a schematic diagram of fluid velocities within the cyclonicinlet diverter of FIG. 5 as the inlet flow travels beyond the swirlplates toward the end caps of the inlet diverter.

FIG. 19 is another schematic diagram of fluid velocities within thecyclonic inlet diverter of FIG. 5 as the inlet flow travels beyond theswirl plates toward the end caps of the inlet diverter.

FIG. 20 is yet another schematic diagram of fluid velocities within thecyclonic inlet diverter of FIG. 5 as the inlet flow travels beyond theswirl plates toward the end caps of the inlet diverter.

Those skilled in the art will appreciate and understand that, accordingto common practice, various features and elements of the drawingsdescribed above are not necessarily drawn to scale, and that thedimensions and relative positions between the features or elements maybe expanded, reduced or otherwise altered to more clearly illustrate thevarious embodiments of the present disclosure depicted therein.

DETAILED DESCRIPTION

The following description, in conjunction with the accompanyingdrawings, is provided as an enabling teaching or disclosure of exemplaryembodiments of a cyclonic inlet diverter, typically for use within alinear or elongate multi-phase separator vessel or similar waterclarification system for a separating a mixed or multi-phase fluid intoits separate constituents, or for clarifying the primary constituent,such as water, from the other constituents, such as oil, gases andvapors, or particular matter, and the like. In one aspect themulti-phase separator vessel or water clarification system can be usedor incorporated into a salt water disposal (SWD) facility or other waterprocessing facility that receives contaminated water from one or morehydrocarbon-producing wells. It will be appreciated, however, that otherapplications for the cyclonic inlet diverter and for the multi-phaseseparator vessel, in addition to the clarification of produced oilywater from hydrocarbon production wells, are also possible andconsidered to fall within the scope of the present disclosure.

The disclosure further includes one or more methods for initiating theseparation of the separate constituents of the mixed or multi-phasefluid using the cyclonic inlet diverter. As described below, thecyclonic inlet diverter apparatus and methods can provide severalsignificant advantages and benefits over other systems and methods forinitiating the separation of the mixed or multi-phase fluid currentlyavailable in the art. However, the recited advantages are not meant tobe limiting in any way, as one skilled in the art will appreciate thatother advantages may also be realized upon practicing the presentdisclosure.

Furthermore, those skilled in the relevant art will recognize thatchanges can be made to the described embodiments while still obtainingthe beneficial results. It will also be apparent that some of theadvantages and benefits of the described embodiments can be obtained byselecting some of the features of the embodiments without utilizingother features, and that features from one embodiment may be combinedwith features from other embodiments in any appropriate combination. Forexample, any individual or collective features of method embodiments maybe applied to apparatus, product or system embodiments, and vice versa.Accordingly, those who work in the art will recognize that manymodifications and adaptations to the embodiments described are possibleand may even be desirable in certain circumstances, and are a part ofthe disclosure. Thus, the present disclosure is provided as anillustration of the principles of the embodiments and not in limitationthereof, since the scope of the invention is to be defined by theclaims.

Referring now in more detail to the drawing figures, FIGS. 1-4illustrate one embodiment of a linear or elongate multi-phase separator10 or similar water clarification system for a separating a mixed ormulti-phase fluid into its separate constituents. The multi-phaseseparator 10 can be configured to receive a multi-phase fluid, includingbut not limited to produced fluids from oil production facilities, andseparate the individual phases and components of the multi-phase fluidinto separate streams of substantially clarified components. Themulti-phase fluid can come straight from one or more producingwellheads, or in the alternative may be oily water that is receivedafter passing through an earlier or upstream oil/water separationprocess. In one representative embodiment an inlet stream of producedmulti-phase fluid may comprise a water component greater than or about75% to 95% by volume, an oil component less than or about 25% to 5% byvolume, a gas component in solution, and a particulate matter componentthat is less than or about 5% by volume. Upon passing through themulti-phase separator 10, the same multi-phase fluid will have beenseparated into an oil outlet stream, a gas outlet stream, discreteaccumulations of solids and sludge that can be periodically removed orflushed from the separation system, and a primary clean water outletstream having less than or about a desired upper threshold limit of oil(or under appropriate conditions less than or about 100 ppm of oil), agreatly-reduced amount of gas in solution, and with any entrainedparticulate matter in suspension being less than or about, for example,200 microns in size.

As can be seen in the drawings, the linear or elongate multi-phaseseparator 10 generally comprises a separator vessel 20 havingcylindrical body 22 with a circular cross-section, and can furtherinclude a rounded inlet end cap 24 at an inlet end 23, and an outlet endcap 26 at an outlet end 29, which in one aspect can be partiallyhemispherical. It will be understood, however, that other shapes(including but not limited to oblong, square, or other non-circularcross-sectional shapes and end caps), inclinations (substantiallyhorizontal or vertical), and configurations for the multi-phaseseparator 10 are also possible and considered to fall within the scopeof the present disclosure.

An inlet flow of mixed or multi-phase fluid (including but not limitedto the produced oily water described above) can be introduced into thepartially-filled separator vessel 20 at the inlet end 23, such asthrough the inlet end cap 24, and from there directed to gradually flowforward toward the discharge or outlet end 29, at low speed and with amaximum retention time, so as to encourage natural gravity-basedseparation of the components of the multi-phase fluid. In the saltwaterdisposal (SWD) application referenced above, the inlet flow of producedoily water into the water clarification system generally includes gasesand vapors, oil, water, and particulate matter (such as sand), and canfurther include additional impurities or contaminants such sludge, dirt,semisolid paraffins, and the like.

As shown in the drawings, the inlet flow is introduced into thepartially-filed separator vessel 20 through the cyclonic inlet diverter40 that can be internally mounted within the separator vessel 20adjacent the inlet end cap 24 and above the internal fluid level 14 ofthe separator vessel 20, whether horizontal or vertical. The cyclonicinlet diverter 40 is configured to provide an initial separation of thevarious constituents or components of the inlet flow of mixed ormulti-phase fluid. As described in detail below, for instance, the inletdiverter 40 can be configured to divert or split the inlet flow from thefluid source into sub-streams having substantially equal flow rates, andthen impart a cyclonic motion to each the sub-streams that provides foran initial centrifugal separation of the mixed constituents. A majorityportion of each sub-stream constituent can then be directed out of theinlet diverter 40 through different outlet ports, resulting in aninitial separation of the inlet flow that improves the overallefficiency of the multi-phase separator 10. Although illustrated assplitting the inlet flow into two equal sub-streams, it is foreseen thatthe inlet diverter may be modified into a single stream device or tosplit the inlet flow into more than two sub-streams.

It will be appreciated that cyclonic inlet diverter 40 is not requiredto achieve an initial high separation efficiency of the fluidconstituents. For example, in one aspect an initial separationefficiency of the inlet diverter 40 can be between about 60% to 80%,which can be sufficient to increase the overall separation efficiency ofthe multi-phase separator 10 or separation system to between about 95%to 99%. Additionally, the cyclonic inlet diverter 40 may be adapted orconfigured for the specific composition and flow rate of the inlet flowbeing introduced into the multi-phase separator 10.

Generally, the cyclonic inlet diverter 40 is configured for high butcontrolled and carefully directed flow velocities to initiate separationof constituents via dynamic centrifugal action, as described in moredetail below (see FIGS. 16-20 ). In contrast, the multi-phase separator10 can be configured for reduced fluid flow velocities and thelow-turbulence movement of fluids. For example, after initial separationof the constituents by the cyclonic inlet diverter 40, the multi-phaseseparator 10 provides for full or high efficiency separation of theconstituents through improved low velocity, laminar flow, gravity-basedseparation. To perform this function, the multi-phase separator 10 caninclude additional internal components and configurations that encouragelow velocity laminar flow from the inlet end 23 through to the outletend 29, thereby fully utilizing the entire length of the separatorvessel 20 to encourage continuous separation of the constituents.

It will be further appreciated that the overall system, including boththe multi-phase separator 10 and the cyclonic inlet diverter 40 enclosedtherein, is scalable to accommodate a wide range of flow rates. Inaddition, the cyclonic inlet diverter 40 and the multi-phase separator10 can be function through a wide range of pressures, ranging from lowpressure (partial vacuum), non-pressurized (i.e. atmosphericconditions), to high pressure conditions (for separation systemsdesigned for high pressure fluid flows), up to and about fluid pressuresof 3000 psi. It will be appreciated that the pressurization state isdetermined by the multi-phase separator 10, with the cyclonic inletdiverter 40 being installed as an internal component.

With continued reference to FIGS. 1-4 , the separator vessel 20 housingthe components that together form the multi-phase separator 10 orseparation system may be horizontally disposed above a ground surface,as illustrated in the horizontal embodiment shown in the drawings. Inone representative embodiment the separator vessel 20 is tubular with alength of about 240″ (20′) and a diameter of about 72″ (6′). As notedabove, however, the separator vessel 20 is scalable in size toaccommodate a wide range of flow rates. For the horizontal embodiment ofthe multi-phase separator 10 illustrated in the drawings, the separatorvessel 20 includes a longitudinal or centerline axis 21 that defines ahorizontal centerline plane 25 and a vertical centerline plane 27, withthe multi-phase fluid generally moving along the longitudinal axis 21(with some transverse flow components) from the inlet end 23 toward theoutlet end 29 throughout the separation process. Although not shown, itis foreseen that the separator vessel may also be vertically disposedabove the ground surface.

In addition to the cyclonic inlet diverter 40 being internally mountedwithin the separator vessel 20 adjacent the inlet end cap 24, themulti-phase separator 10 can also include a plurality of baffle platesspaced along the length of the horizontally disposed separator vessel20, from the inlet end toward the discharge end. The baffle plates 70can serve to sub-divide a separation portion of the separator vesselinto a plurality of separation zones 34. In the illustrated embodiment,for example, there are three baffle plates 70 sub-dividing theseparation portion into four separation zones 34, 36, followed by a weirplate 80 defining an oil outlet portion/zone 38 that is separate fromthe separation portion/zones 34, 36. However, it is foreseen that adifferent number of baffle plates be used to decrease or increase thenumber of separation zones.

Generally, the baffle plates 70 extend laterally across the interior ofthe separator vessel (perpendicular to the longitudinal axis) to form asolid connection with the lower and center portions of the separatorsidewall. The baffle plates can extend above the fluid level 16 of thebulk fluid 14 in the separator vessel, but generally do not extend tothe top portions of the separator sidewall, so as to provide an upperhead space 30 in the separator vessel that allows for the free flow ofgas and vapors from the inlet end 23 to the discharge end 29, where thegas/vapor constituent can exit the separator vessel 20 through a gasoutlet 35. A lowermost portion 72 of each baffle plate 70 can be solidto prevent the flow of fluid along the bottom of the separator vessel,helping to create a lower quite zone that allows for sludge and solidsto gently settle toward the bottom in the first three separation zones34. The middle and upper portions of each baffle plate includes slots orapertures 74 that serve to stratify the fluid as it flows through thebaffle plates, thereby improving retention time. The waterlayer/constituent is withdrawn from a water outlet 37 located at thebottom of the final (or fourth) separation zone 36.

The multi-phase separator 10 can further include a weir plate 80proximate to but spaced from the discharge end serves to divide an oiloutlet portion/zone 38 from the separation zones 34, 36 defined by theplurality of baffle plates 70. The weir plate 80 extends laterallyacross the interior of the separator vessel (perpendicular to thelongitudinal axis) to form a solid connection with the lower and centerportions of the separator sidewall. The weir plate 80 can also beentirely solid and impenetrable across the face thereof, causing theoily top layer/constituent of the fluid flow to pour over the top edgeand down into the oil outlet portion 38. The height of the weir plate 80can be less than the height of the baffle plates 70, and can serve toset the height of the fluid level 16 within the separator vessel. Theoil layer/constituent is withdrawn from an oil outlet 39 located at thebottom of the oil outlet portion/zone 38.

It will be appreciated that the separator vessel 20 generally has awelded steel construction, and that most, if not all, of the separatecomponents enclosed therein, such as the baffle plates 70, the weirplate 80, and any additional fittings and piping, generally also have awelded steel construction. If pressurized, the separator vessel 20 andthe additional fittings and piping can be compliant with Section VIII ofthe ASME Boiler and Pressure Vessel Code. Moreover, as shown below, thecyclonic inlet diverter 40 can also have a welded steel construction,although it is foreseen that the inlet diverter may also been formedwith a plastic or fiberglass construction, given its location entirelywithin the volume defined by the separator vessel.

One embodiment of the cyclonic inlet diverter 40 is shown in furtherdetail in FIGS. 5-15 . Relative to the separator vessel 20, the inletdiverter 40 generally comprises a much smaller enclosed tubular body 42defining a diverter longitudinal axis 41, and having opposed end walls48, a tubular sidewall 46 extending between the opposed end walls 48,and a midline inlet port 44 located midway between the end walls. Thediverter longitudinal axis 41 is oriented substantially parallel withand above the separator vessel's horizontal centerline plane 25, and issubstantially perpendicular to the separator vessel's verticalcenterline plane 27. The representative embodiment of the inlet diverter40 shown in the drawings can have a length of about 36″ (3′) and adiameter of about 9″, but it is understood that the inlet diverter 20,like the multi-phase separator 10, is also scalable in size toaccommodate a wide range of flow rates.

The inlet diverter 40 can also include an inlet port 44 that ishorizontally located (i.e. along the diverter longitudinal or centerlineaxis) midway between the opposed end walls, and that can be verticallylocated in an offset position to the longitudinal axis (i.e. above orbelow a diverter horizontal centerline plane) so the inlet flow entersdirectly into the upper or lower half or hemisphere of the inletdiverter. Thus, in one aspect the fluid flow through the inlet port 44can be substantially tangential to an upper or lower portion,respectively, of the inlet diverter tubular sidewall 46. In theembodiment of the cyclonic inlet diverter 40 shown in FIGS. 5-15 , forexample, the inlet port 44 is vertically offset above the diverter'shorizontal centerline plane 45, so that the inlet flow enters thetubular body 42 substantially tangential to the upper portion of theinlet diverter's tubular sidewall 46 and is directed downwardly uponreaching the far portion of the sidewall to initiate the cyclonic motionof the fluid flow. The inlet port 44 can include welded piping to aflange connection 43 that is, in turn, bolted to an internal inletflange within the separator vessel 20. In one aspect the inlet diverter40 can be entirely supported within the separator vessel by the inletport flange and piping.

Internal components, such as a splitter plate 50 positioned within acenter portion of the inlet diverter with a forward edge 52 aligned withthe center of the inlet port 44, can split the inlet fluid flow into afirst sub-stream and a second sub-stream as it enters through the inletport 44, with each sub-stream flowing outward through the tubular body42 toward an end wall 48. With the inlet port 44 located above thediverter horizontal centerline plane, the splitter plate 50 and roundtubular sidewall 46 of the tubular body 42 can naturally initiate thecyclonic motion of the fluid as it flows around and downwardly acrossthe far portion of the tubular sidewall, following the circular contourof the inner sidewall surfaces. Constrained by the tubular sidewall 46,the sub-streams also flow laterally outward and away from the splitterplate 50 until they encounter additional internal components, such asswirl plates 54, which can be positioned on each side of the splitterplate 50 to increase the cyclonic motion of the sub-streams. Throughcentrifugal action or separation, the cyclonic flows can quickly pushthe heavier constituents (solids and water) further outward toward theinterior rounded surfaces of the tubular sidewall than the lighterconstituents (gas and oil).

As their name suggests, the swirl plates 54 can have angled surfacesconfigured to increase the cyclonic motion in the first and secondsub-streams within the tubular body. In one aspect the swirl plates canbe located about one complete revolution from the splitter plate 50 andinlet port 44, with the lower hemispheres 56 of the swirl plates 54extending completely across the lower half of the tubular body toconstrain and control the sub-streams flowing through the splitterplate. The upper hemisphere of swirl plates can be split, with inletsides 57 of the split being angled downstream or away from the splitterplate, and the far sides 58 of the split being angled upstream or towardthe splitter plate, so as to capture and direct the steams through aV-shaped passage defined by the two angled surfaces. Furthermore, thetrailing edge of the upper hemisphere inlet side angled surface mayinclude an additional rigid flap portion 59 that is angled to furthercontrol or concentrate the sub-streams as they pass through the V-shapedpassage, thereby increasing the cyclonic motion. It will be appreciatedthat additional modifications or other designs for the internalcomponents of the inlet diverter 40, including but not limited to thesplitter plate 50 and the swirl plates 54, are also possible andconsidered to fall within the scope of the present disclosure.

The cyclonic inlet diverter shown in FIGS. 5-15 can further includemultiple outlet ports on each end of the tubular body 42, with aseparate outlet port for a majority portion of each constituent of themixed fluid on each side. For instance, the tubular body 42 of the inletdiverter can include an elongate aperture or slot 60 formed through thebottom sidewall portions of the tubular body on each side of thesplitter plate 50, which can serve to define particulate matter orsolids outlet ports. In one aspect the solids outlet ports can furtherinclude an internal fin 61 on the downstream side of the solids outletport 60 to better capture and re-direct the solids constituent of thesub-stream downward through the outlet port. Particulate matter andother solids will be carried in a portion of the fluid, so that thematerial exiting the solids outlet port 60 will generally form a fallingsheet of dirty liquid.

The tubular body 42 of the inlet diverter can also include an aperture62 formed through each opposing end wall 48 and centered about thediverter longitudinal axis 41, which can serve as a gas outlet port 62.

As shown in the drawings, the tubular body 42 can further include afirst radial aperture 64 formed through the lateral sidewall portions ofthe tubular body adjacent to each opposing end wall 48, which can serveas a water outlet port. In one aspect the water outlet port 64 can beformed into the inlet side of the lateral sidewall portion, so the fluidpassing through the port is directed back onto the interior surface ofthe inlet end cap 24 of the separator vessel 20, and then flows downwardalong the interior surface of the end cap 24 as a substantially laminarsheet, into the bulk fluid 14 contained in the separator vessel. Thisfeature can function to reduce turbulence as the inlet streams enter thebulk fluid 14, as well as to increase the retention time of the newlydelivered fluid within the multi-phase separator.

The tubular body 42 can further include a second radial aperture 66formed through the lateral sidewall portions of the tubular body 42between each first aperture 64 and the midline inlet port 44, which canserve as an oil outlet port. The oil outlet port 66 also can be formedinto the inlet side lateral sidewall portion, so the fluid passingthrough the oil outlet port is also directed back onto the interiorsurface of the inlet end cap 24 of the separator vessel 20, and thenflows downward along the interior surface as a substantially laminarsheet, into the bulk fluid 14 contained in the separator vessel 20. Inmost cases where the oil constituent of the mixed fluid is less than thewater constituent, the oil outlet port can be smaller than the wateroutlet port.

It is understood that the representative embodiment of the cyclonicinlet diverter 40 shown in FIGS. 5-15 is generally configured tointerface with the linear or multi-phase separator 10 shown in FIGS. 1-4, and which together can be configured or tailored for separating theconstituents of the produced multi-phase fluid described above. It willbe further understood that both the cyclonic inlet diverter 40 and theoverall multi-phase separator 10 are fully customizable andreconfigurable as desired by one of skill in the art, and that each ofthe inlet diverter 40, the inlet port 44, the internal components 50,54, and the outlet ports 60, 62, 64, 66 can be customized or adjustedfor both a particular flow rate and for a specific mixture ofconstituents.

Although not shown in detail, the multi-phase separator 10 can furtherinclude an inlet flow speed gate, or control valve, upstream of thecyclonic inlet diverter 40. The inlet flow speed gate can be used tocontrol the velocity of the inlet flow into the cyclonic inlet diverter,so as to maintain a predefined velocity of the fluid in variable (e.g.generally decreasing) flow rate conditions. It will be appreciated thatmaintaining the speed of the fluid entering the inlet diverter 40 canprovide for an optimal separation of the fluid constituents, and canalso serve to reduce emulsions of the oil and water mixture, improvingthe overall performance of the multi-phase separator 10. In one aspectthe inlet flow speed gate can be a reed-type valve with a plastic ormetal reed member. However, other types of speed-based flow controlvalves are also possible and considered to fall within the scope of thepresent disclosure.

With reference to FIGS. 16-20 , during operation of the multi-phaseseparator 10 the inlet flow speed gate (not shown) can control thevelocity of the inlet flow of a mixed or produced multi-phase fluid to adesired range of values. As shown in FIG. 16 , the inlet flow is firstreceived through the inlet port 44, upon which it immediately encountersthe splitter plate that divides and redirects the inlet flow intohorizontal, oppositely-directed sub-streams. Together with the interiorrounded surfaces of the tubular sidewall 46, the inlet port 44 and thesplitter plate 50 initiate the cyclonic motion of the fluid around thediverter longitudinal axis 41 as it flows laterally outward and awayfrom the midline splitter plate 50.

With reference to FIG. 17 , the sub-streams can then encounter the swirlplates 54, which can amplify and focus the cyclonic motion of thesub-streams around the diverter longitudinal axis 41. Throughcentrifugal action/separation, the cyclonic flows quickly push theheavier constituents (solids and water) further outward toward theinterior rounded surfaces and end walls 48 of the tubular vessel 42 thanthe lighter constituents (gas and oil), thereby establishing an initialseparation between the constituents of the mixed or produced multi-phasefluid.

With reference to FIG. 18-20 , the different fluid constituents can befurther separated via their respective outlet ports. With regards to theany particulate matter or solids included in the inlet flow, forexample, the cyclonic motion imparted by the swirl plates and theplacement of the solids outlet ports 60 in the bottom sidewall portionof the tubular body, along with the internal fins 61, preferentiallydirects any solid particles in the produced fluid, together with aportion of the fluid, directly downward out of the inlet diverter 40, inthe form of a liquid sheet falling toward the bottom of the separatorvessel 20.

With regards to the water constituent of the inlet flow, the cyclonicmotion imparted by the swirl plates 54 and the placement of the largerwater outlet port 64 at the far opposite ends of the tubular body 42directs a majority portion of the heavier water constituent outwards andback towards the inlet end cap 24 of the separator vessel 20, placingthe water constituent at the furthest point from the liquid outlets ofthe separator vessel 20 to allow for the maximum retention time allowedby the design of the multi-phase separator 10.

With regards to the oil constituent of the inlet flow, the cyclonicmotion imparted by the swirl plates 54 and the placement of the smalleroil outlet port 66 (inward but adjacent to the water outlet port)directs a majority portion of the oil constituent towards the inlet endcap 24 of the separator vessel 20, also placing the lighter oilconstituent at the furthest point from the liquid outlets (but in aseparate stream from the water constituent), so as to allow for themaximum retention time allowed by the design of the multi-phaseseparator 10.

With regards to the gas constituent of the inlet flow, the gasconstituent is least affected by the cyclonic motion imparted by theswirl plates 54, so that the placement of the gas outlet ports 62through the end walls 48 of the tubular body 42, and centered about thediverter longitudinal axis 41, directs the majority portion of the gasconstituent out the gas outlet ports 62 of the apparatus 40 and into thehead space 30 of the separator vessel 20. Moreover, any residual gasthat remains entrained within the liquid water and oil constituents cancontinue to bubble up from the bulk fluid 14 as it slowly flows from theinlet end 23 to the discharge end 29 of the separator vessel 20.

As indicated above, the elongate multi-phase separator and the cyclonicinlet diverter enclosed therein have been described herein in terms ofpreferred embodiments and methodologies considered by the inventor torepresent the best mode of carrying out the invention. It will beunderstood by the skilled artisan, however, that a wide range ofadditions, deletions, and modifications, both subtle and gross, may bemade by those of skill in the art to the illustrated and exemplaryembodiments of the elongate multi-phase separator and the cyclonic inletdiverter without departing from the spirit and scope of the presentdisclosure.

What is claimed is:
 1. A method of separating a flow of multi-phasefluid including at least a gas constituent, an oil constituent, and awater constituent, the method comprising: directing the flow ofmulti-phase fluid through an inlet opening of an enclosed tubular body,the tubular body comprising a tubular sidewall with opposed end wallscentered about a longitudinal axis, the tubular body also including atleast one axial outlet aperture formed through the opposed end walls andat least one radial outlet aperture formed through the tubular sidewallat a location spaced from the inlet opening; directing the flow ofmulti-phase fluid onto at least one swirl plate positioned within thetubular body between the inlet opening and the at least one axial outletaperture and the at least one radial outlet aperture, the at least oneswirl plate having angled surfaces configured to impart a cyclonicmotion of the flow of multi-phase fluid within the tubular body so as toinitiate separation of the constituents of the multi-phase fluid withinthe tubular body: directing at least a majority portion of the gasconstituent axially outward from the tubular body through the at leastone axial outlet aperture; and directing at least a majority portion ofthe oil constituent and at least a majority portion of the waterconstituent radially outward from the tubular body through the at leastone radial outlet aperture.
 2. The method of claim 1, wherein directingthe at least a majority portion of the oil constituent and the at leasta majority portion of the water constituent radially outward from thetubular body further comprises: directing a majority portion of thewater constituent radially outward through a first radial apertureproximate an end wall that includes the at least one axial outletaperture; and directing a majority portion of the oil constituentradially outward through a second radial aperture spaced from theopposed end wall.
 3. The method of claim 2, wherein a center of thefirst radial aperture is in angular alignment, with respect to thelongitudinal axis of the tubular body, with a center of the secondradial aperture.
 4. The method of claim 2, wherein the first radialaperture and the second radial aperture are substantially circular. 5.The method of claim 1, further comprising directing at least a majorityportion of a solids constituent included in the flow of multi-phasefluid out of the tubular body in a radially outward and downwarddirection through at least one elongate aperture formed through a bottomportion of the tubular body.
 6. The method of claim 1, furthercomprising splitting the flow of multi-phase fluid into a first streamand a second stream upon entry of the flow of multi-phase fluid into thetubular body through the inlet opening, the first stream and the secondstream being directed in opposite directions along the longitudinal axisof the tubular body to the opposed end walls.
 7. The method of claim 6,wherein splitting the flow of multi-phase fluid into a first stream anda second stream further comprises directing the flow of multi-phasefluid onto a forward edge of a splitter plate located within the tubularbody of the cyclonic separator, and wherein directing the flow ofmulti-phase fluid onto the at least one swirl plate further comprisesdirecting the first stream and the second stream onto swirl plateslocated downstream and on opposite sides of the splitter plate.
 8. Themethod of claim 7, wherein the inlet opening further comprises a radialinlet aperture formed through a center portion of the tubular sidewalland equally spaced between the opposed end walls, and wherein thesplitter plate is located at the center portion of the tubular sidewalland aligned with the inlet opening.
 9. The method of claim 6, whereindirecting the at least a majority portion of the gas constituent axiallyoutward from the tubular body further comprises directing a majorityportion of the gas constituent of the first stream and the second streamaxially outward through axial apertures formed through each of theopposed end walls.
 10. The method of claim 6, wherein directing at leasta majority portion of the oil constituent and at least a majorityportion of the water constituent radially outward from the tubular bodyfurther comprises directing a majority portion of the oil constituentand a majority portion of the water constituent radially outward througha first radial aperture proximate each opposed end wall and a secondradial aperture adjacent each first radial aperture to form opposingpairs of first and second radial apertures.
 11. The method of claim 1,further comprising controlling an average velocity of the flow ofmulti-phase fluid so as to be maintained above a minimum inlet velocityfor imparting the cyclonic motion within the tubular body.
 12. A methodfor initiating the separation of constituents of a flow of multi-phasefluid including a gas constituent, an oil constituent, a waterconstituent, and a solids constituent, the method comprising: directingthe flow of multi-phase fluid through an inlet opening of an enclosedtubular body, the tubular body comprising a tubular sidewall withopposed end walls centered about a longitudinal axis, the tubular bodyincluding an inlet opening, at least one axial outlet aperture formedthrough the opposed end walls, at least one radial outlet apertureformed through the tubular sidewall at a location spaced from the inletopening, and at least one elongate aperture formed through a bottomportion of the tubular body; directing the flow of multi-phase fluidonto at least one swirl plate positioned within the tubular body betweenthe inlet opening and the at least one axial outlet aperture and the atleast one radial outlet aperture, the at least one swirl plate havingangled surfaces configured to impart a cyclonic motion of the flow ofmulti-phase fluid within the tubular body so as to initiate separationof the constituents of the multi-phase fluid within the tubular body:directing at least a majority portion of the gas constituent axiallyoutward from the tubular body through the at least one axial outletaperture; directing at least a majority portion of the oil constituentand at least a majority portion of the water constituent radiallyoutward from the tubular body through the at least one radial outletaperture; and directing at least a majority portion of the solidsconstituent included radially outward and downward direction from thetubular body through the at least one elongate aperture formed through abottom portion of the tubular body.
 13. The method of claim 12, furthercomprising splitting the flow of multi-phase fluid into a first streamand a second stream upon entry of the flow of multi-phase fluid into thetubular body through the inlet opening, the first stream and the secondstream being directed in opposite directions along the longitudinal axisof the tubular body to the opposed end walls.
 14. The method of claim13, wherein splitting the flow of multi-phase fluid into a first streamand a second stream further comprises directing the flow of multi-phasefluid onto a forward edge of a splitter plate located within the tubularbody of the cyclonic separator, and wherein directing the flow ofmulti-phase fluid onto the at least one swirl plate further comprisesdirecting the first stream and the second stream onto swirl plateslocated downstream and on opposite sides of the splitter plate.
 15. Themethod of claim 14, wherein the inlet opening further comprises a radialinlet aperture formed through a center portion of the tubular sidewalland equally spaced between the opposed end walls, and wherein thesplitter plate is located at the center portion of the tubular sidewalland aligned with the inlet opening.
 16. The method of claim 13, whereindirecting the at least a majority portion of the gas constituent axiallyoutward from the tubular body further comprises directing a majorityportion of the gas constituent of the first stream and the second streamaxially outward through axial apertures formed through each of theopposed end walls.
 17. The method of claim 13, wherein directing atleast a majority portion of the oil constituent and at least a majorityportion of the water constituent radially outward from the tubular bodyfurther comprises directing a majority portion of the oil constituentand a majority portion of the water constituent radially outward througha first radial aperture proximate each opposed end wall and a secondradial aperture adjacent each first radial aperture to form opposingpairs of first and second radial apertures.
 18. The method of claim 12,further comprising controlling an average velocity of the flow ofmulti-phase fluid so as to be maintained above a minimum inlet velocityfor imparting the cyclonic motion within the tubular body.
 19. A methodof separating the constituents of the flow of multi-phase fluidcomprising the method of claim 12 and further comprising collecting eachof the majority portion of the gas constituent, the majority portion ofthe oil constituent, the majority portion of the water constituent, andthe majority portion of the solids constituent within an elongateseparator vessel having an inlet end, a discharge end opposite the inletend, and separator sidewalls extending between the inlet end and thedischarge end, wherein the separator vessel is partially filled with abulk fluid so as to define a fluid level of the bulk fluid and a headspace above the bulk fluid, wherein the tubular body is positionedwithin the separator vessel proximate the inlet end of the separatorvessel and above the fluid level of the bulk fluid, and wherein themajority portion of the gas constituent is configured to flow directlyinto the head space of the separator vessel, the majority portion of theoil constituent and the majority portion of the water constituent areconfigured to flow toward an inlet end cap of the separator vessel, andthe majority portion of the solids constituent is configured to flowdownwards into the bulk fluid contained within the separator vessel. 20.The method of claim 19, wherein the separator vessel includes aseparator longitudinal axis defining a horizontal centerline plane and avertical centerline plane, and wherein a longitudinal axis of thetubular body is orientated substantially perpendicular to the verticalcenterline plane of the separator vessel and substantially parallel withand spaced above the horizontal centerline plane of the separatorvessel.